ME 303
Tutorial 2
Problem 1:
A brass slab of dimensions 40x1000 mm and height of 50 mm is to be compressed to final
height of 20 mm in a hydraulic press at room temperature with ram velocity of 15 m/min. The
material properties of the workpiece is given as: K = 800 MPa, n = 0.33, C = 14 MPa , m = 0.2.
a) Calculate the press force if = 0.2 (consider maximum capacity)
b) Assuming sticking friction all over the entire surface and hot working at 800 C , what
will be the press force required for the process?
Solution:
The given parameters for the question can be listed as follows:
𝑤 = 1000 𝑚𝑚
ℎ0 = 50 𝑚𝑚
ℎ1 = 20 𝑚𝑚
= 0.2
a) The volume of the slab remains constant, resulting in the following expression:
𝑉0 = 𝑉1 ⇒ (40)(1000)(50) = (2𝑎)(1000)(20)
⇒ 𝑎 = 50 𝑚𝑚
Then, it is necessary to investigate the assumptions for the friction. Note that the friction in the
core is sticking friction up to 𝑥 = 𝑥1 . Also, the friction can be said as sliding friction (Coulomb
friction) from 𝑥 = 𝑥1 to 𝑥 = 𝑎 as seen from the figure below:
𝑆𝑙𝑖𝑑𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑆𝑡𝑖𝑐𝑘𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑆𝑙𝑖𝑑𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛
𝑅𝑒𝑔𝑖𝑜𝑛 𝑅𝑒𝑔𝑖𝑜𝑛 𝑅𝑒𝑔𝑖𝑜𝑛
𝑆𝑙𝑎𝑏
𝑥
−𝑎 −𝑥1 𝑥1 𝑎
In our question, let us calculate 𝑥1 to realize the case:
ℎ 1
𝑥1 = 𝑎 − ln ( )
2𝜇 2𝜇
(20 𝑚𝑚) 1
⇒ 𝑥1 = (50 𝑚𝑚) − ln ( ) ⇒ 𝑥1 = 4.2 𝑚𝑚
2(0.2) 2(0.2)
Type of friction at the die/workpiece interface:
• Sliding Friction: exponential variation
• Sticking Friction: linear (more severe conditions of friction)
• Mixed Friction: linear at the middle (sticking) and exponential at the edge (sliding)
It means that the friction can be assumed as sliding friction for this condition. This is because
the sticking friction region is very small when compared to the entire surface.
𝑆𝑙𝑖𝑑𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑆𝑙𝑖𝑑𝑖𝑛𝑔 𝐹𝑟𝑖𝑐𝑡𝑖𝑜𝑛
𝑅𝑒𝑔𝑖𝑜𝑛 𝑅𝑒𝑔𝑖𝑜𝑛
𝑆𝑙𝑎𝑏
𝑥
−𝑎 = − 50 𝑚𝑚 −𝑥1 = −4 𝑚𝑚 𝑥1 = 4 𝑚𝑚 𝑎 = 50 𝑚𝑚
The flow stress can be found by
𝑛
50 𝑚𝑚 0.33
𝜎 = 𝐾𝜀 ⇒ 𝜎 = (800𝑀𝑃𝑎) [ln ( )]
20 𝑚𝑚
⇒ 𝜎 = 777 𝑀𝑃𝑎 = 𝑌
With the assumption of sliding friction, average pressure can be expressed as follows:
𝑃𝑎𝑣 ℎ 2𝜇𝑎
= (𝑒 ℎ − 1)
𝑌 2𝜇𝑎
(20 𝑚𝑚) 2(0.2)(50 𝑚𝑚)
⇒ 𝑃𝑎𝑣 = (777 𝑀𝑃𝑎) (𝑒 (20 𝑚𝑚) − 1)
2(0.2)(50 𝑚𝑚)
⇒ 𝑃𝑎𝑣 = 1335 𝑀𝑃𝑎
Finally, the press force is calculated as
𝐹 = 𝑃𝑎𝑣 𝐴 ⇒ 𝐹 = (1335 𝑀𝑃𝑎)(100𝑚𝑚 𝑥 1000𝑚𝑚)
⇒ 𝐹 = 133.5 𝑀𝑁
b) For hot working, the flow stress is calculated using the following equation:
𝜎 = 𝐶𝜀̇ 𝑚 𝑤ℎ𝑒𝑟𝑒 𝜀̇ = 𝑉/ℎ
0.2
15
𝑚/𝑠
⇒ 𝜎 = (14𝑀𝑃𝑎) [ 60 ]
(20 𝑚𝑚)
⇒ 𝜎 = 23.2 𝑀𝑃𝑎 = 𝑌
With the assumption of sticking friction, average pressure can be expressed as follows:
𝑃𝑎𝑣 0.5𝑎
= 1+
𝑌 ℎ
0.5 (50 𝑚𝑚)
⇒ 𝑃𝑎𝑣 = (23.2𝑀𝑃𝑎) (1 + )
(20 𝑚𝑚)
⇒ 𝑃𝑎𝑣 = 52.2 𝑀𝑃𝑎
Finally, the press force is calculated as
𝐹 = 𝑃𝑎𝑣 𝐴 ⇒ 𝐹 = (52.2 𝑀𝑃𝑎)(100𝑚𝑚 𝑥 1000𝑚𝑚)
⇒ 𝐹 = 5.22 𝑀𝑁
Problem 2:
An axisymmetric upsetting process is carried out on an annealed cylindrical steel workpiece at
the room temperature. The original diameter of the specimen is 50 mm. The initial height of the
specimen was 75 mm, which is reduced to 60 mm after the upsetting operation. The associated
flow equation is provided as 𝑓 = 6000.3 𝑀𝑃𝑎. Assume sliding friction, where the friction
coefficient between the die and the workpiece is 0.20.
a) Determine the equivalent strain.
b) Calculate the average interface pressure at the end of the process.
c) Find the upsetting force at the end of the process.
Solution:
The given parameters:
𝑑0 = 50𝑚𝑚, ℎ0 = 75𝑚𝑚, ℎ1 = 60𝑚𝑚, 𝐾 = 600, 𝑛 = 0.3
a) The equivalent strain is easy to calculate since the initial and final height of the
workpiece are known:
ℎ0 75𝑚𝑚
𝜀𝑒𝑞 = ln ( ) = ln ( ) = 0.223
ℎ1 60𝑚𝑚
b) The diameter of the slab at the end of the process can be determined by volume
constancy:
𝜋𝑑02 𝜋𝑑12 ℎ0
ℎ0 = ℎ1 ⇒ 𝑑1 = 𝑑0 √ = 55.9 𝑚𝑚
4 4 ℎ1
Since the average interface pressure is asked for the instant at the end of the process, the
parameters at that instant should be used. For sliding friction assumption, it is calculated
as follows:
𝑃𝑎𝑣 1 ℎ 2 2µ𝑅 2µ𝑅
= ( ) (𝑒 ℎ − − 1)
𝑌 2 µ𝑅 ℎ
2
(600 ∗ 0.2230.3 )𝑀𝑃𝑎 60𝑚𝑚 2(0.2)(28𝑚𝑚) 2(0.2)(28𝑚𝑚)
𝑃𝑎𝑣 = ( ) (𝑒 60𝑚𝑚 − − 1)
2 (0.2)(28𝑚𝑚) 60𝑚𝑚
⇒ 𝑃𝑎𝑣 = 407.5𝑀𝑃𝑎
c) The upsetting force at the end of the process is determined by the average pressure and
the relevant area:
𝜋𝑑12 𝜋(55.9𝑚𝑚)2
𝐹 = 𝑃𝑎𝑣 = (407.5𝑀𝑃𝑎) ( ) = 1𝑀𝑁
4 4
Problem 3:
A 55 mm diameter billet of annealed low carbon steel with a length of 200 mm is direct cold
extruded to 40 mm diameter using a die with an included angle of 130°. The flow curve of the
material is given as 𝜎𝑓 = 600𝜀 0.21 𝑀𝑃𝑎 with initial flow stress 𝜎𝑓0 = 450 𝑀𝑃𝑎, and the
coefficient of friction is 0.08. Calculate the extrusion force using both;
a) Elementary theory of plasticity
b) Empirical methods
Note: In empirical case, use container friction expression in the elementary theory of plasticity.
Solution:
Given parameters are listed as follows:
𝑑0 = 55 𝑚𝑚 𝑑1 = 40 𝑚𝑚 𝑙0 = 200 𝑚𝑚 𝜎𝑓0 = 450 𝑀𝑃𝑎
2𝛼 = 130 ̊ 𝜇 = 0.08 𝜎𝑓 = 600𝜀 0.21 𝑀𝑃𝑎
a) In the first part, elementary theory of plasticity will be used for computation of extrusion
force. Let us first calculate some required parameters as follows:
𝜋𝑑02
𝐴0 = = 2376 𝑚𝑚2
4
𝜋𝑑12
𝐴1 = = 1257 𝑚𝑚2
4
𝐴0
𝜀𝑒𝑞 = ln ( ) = 0.637
𝐴1
𝜎𝑓 = 600𝜀 0.21 𝑀𝑃𝑎 = 600(0.637)0.21 𝑀𝑃𝑎 = 546 𝑀𝑃𝑎
Note that the mean flow stress should be calculated by the mean of the flow stress found above
& initial flow stress provided in the question. Mean flow stress formula derived from some
integral should not be used here!
𝜎𝑓 + 𝜎𝑓0 546 𝑀𝑃𝑎 + 450 𝑀𝑃𝑎
𝜎𝑓𝑚 = = = 498 𝑀𝑃𝑎
2 2
Since 𝛼 > 45 ̊, the formation of dead zone should be checked first. Note that the effective
forces in dead zone formation are shear force and the die-shoulder friction force.
If dead zone is not formed:
𝛼1 = 65 ̊ 𝜇1 = 0.08
2
𝐹𝑠ℎ𝑒𝑎𝑟 = tan(𝛼1 ) 𝐴0 𝜎𝑓𝑚 = 1691 𝑘𝑁
3
2𝜎𝑓𝑚 𝜀𝑒𝑞 𝜇1 𝐴0
𝐹𝑑𝑖𝑒−𝑠ℎ = = 157 𝑘𝑁
sin(2𝛼1 )
⇒ 𝐹𝑠ℎ𝑒𝑎𝑟 + 𝐹𝑑𝑖𝑒−𝑠ℎ = 1848 𝑘𝑁
If dead zone is formed:
𝛼2 = 45 ̊ 𝜇2 = 0.5
2
𝐹𝑠ℎ𝑒𝑎𝑟 = tan(𝛼2 ) 𝐴0 𝜎𝑓𝑚 = 789 𝑘𝑁
3
2𝜎𝑓𝑚 𝜀𝑒𝑞 𝜇2 𝐴0
𝐹𝑑𝑖𝑒−𝑠ℎ = = 753 𝑘𝑁
sin(2𝛼2 )
⇒ 𝐹𝑠ℎ𝑒𝑎𝑟 + 𝐹𝑑𝑖𝑒−𝑠ℎ = 1542 𝑘𝑁
As observed from the calculations, total of these forces become lower when the dead zone
formed. Therefore, one can conclude that dead zone will occur and associated coefficient should
be used in the relevant computations. (𝛼2 = 45 ̊ 𝜇2 = 0.5)
Once the formation of dead zone is checked, total extrusion force could be calculated as follows:
𝐹𝑖𝑑𝑒𝑎𝑙 = 𝐴0 𝜎𝑓𝑚 𝜀𝑒𝑞 = 753 𝑘𝑁
2
𝐹𝑠ℎ𝑒𝑎𝑟 = tan(𝛼2 ) 𝐴0 𝜎𝑓𝑚 = 789 𝑘𝑁
3
2𝜎𝑓𝑚 𝜀𝑒𝑞 𝜇2 𝐴0
𝐹𝑑𝑖𝑒−𝑠ℎ = = 753 𝑘𝑁
sin(2𝛼2 )
𝐹𝑐𝑜𝑛𝑡−𝑓𝑟𝑖𝑐 = 𝜋𝑑0 𝑙0 𝜎𝑓0 𝜇1 = 1244 𝑘𝑁
⇒ 𝐹 = 𝐹𝑖𝑑𝑒𝑎𝑙 + 𝐹𝑠ℎ𝑒𝑎𝑟 + 𝐹𝑑𝑖𝑒−𝑠ℎ + 𝐹𝑐𝑜𝑛𝑡−𝑓𝑟𝑖𝑐 = 3539 𝑘𝑁
b) The extrusion force is calculated by means of empirical method in this case:
𝑄𝑒 = 0.8 + 1.2𝜀𝑒𝑞 = 1.564
𝐹 ′ = 𝑄𝑒 𝐴0 𝜎𝑓𝑚 = 1850 𝑘𝑁
⇒ 𝐹 = 𝐹 ′ + 𝐹𝑐𝑜𝑛𝑡−𝑓𝑟𝑖𝑐 = 3094 𝑘𝑁
Note that 𝑄𝑒 does not include container friction force in the expression. Thus, the container
friction force (found in the previous part) can be used as a reasonable assumption in this case.
Note also that it may be better to calculate the flow mean stress with the following formula (it
is different than the Siebel’s assumption):
𝐾𝜀 𝑛
𝜎𝑓𝑚 = = 451𝑀𝑃𝑎
𝑛+1
𝐹 = 𝐹 ′ + 𝐹𝑐𝑜𝑛𝑡−𝑓𝑟𝑖𝑐 = 2920 𝑘𝑁
Problem 4:
Steel tubes with an inner diameter of 38 mm are to be drawn over a stationary mandrel of 38
mm in diameter to reduce their outer diameters from of 50 mm to 46 mm. For this purpose, a
0.24
die with included angle of 18° is used. The flow curve is expressed 𝜎𝑓 = 700𝜀𝑒𝑞 𝑀𝑃𝑎 with
initial flow stress 𝜎𝑓0 = 240 𝑀𝑃𝑎. The coefficient of friction between the mandrel and the
workpiece is 0.04 whereas it is 0.07 at the die-shoulder interface. The drawing velocity is 0.5
m/sec.
a) Calculate drawing force.
b) Determine necessary power.
Answer:
Given parameters are listed as follows:
𝑑0 = 50 𝑚𝑚 𝑑1 = 46 𝑚𝑚 𝑑𝑖 = 38 𝑚𝑚 𝜎𝑓0 = 240 𝑀𝑃𝑎
2𝛼 = 18 ̊ 𝜇𝑚 = 0.04 µ = 0.04 𝜎𝑓 = 700𝜀 0.24 𝑀𝑃𝑎
a) The calculations are straightforward. Let us first calculate some required parameters as
follows:
𝜋(𝑑02 − 𝑑𝑖2 )
𝐴0 = = 829 𝑚𝑚2
4
𝜋(𝑑12 − 𝑑𝑖2 )
𝐴1 = = 528 𝑚𝑚2
4
𝐴0
𝜀𝑒𝑞 = ln ( ) = 0.452
𝐴1
𝜎𝑓 = 700𝜀 0.24 𝑀𝑃𝑎 = 700(0.452)0.24 𝑀𝑃𝑎 = 579 𝑀𝑃𝑎
Mean flow stress:
𝜎𝑓 + 𝜎𝑓0 579 𝑀𝑃𝑎 + 240 𝑀𝑃𝑎
𝜎𝑓𝑚 = = = 409 𝑀𝑃𝑎
2 2
No need to check dead zone since 𝛼 < 45 ̊ :
𝛼 = 9 ̊ and 𝜇 = 0.07
Calculate the individual force components:
𝐹𝑖𝑑𝑒𝑎𝑙 = 𝐴1 𝜎𝑓𝑚 𝜀𝑒𝑞 = 98 𝑘𝑁
1
𝐹𝑠ℎ𝑒𝑎𝑟 = tan(𝛼) 𝐴1 𝜎𝑓𝑚 = 17 𝑘𝑁
2
2𝜎𝑓𝑚 𝜀𝑒𝑞 𝜇𝐴1
𝐹𝑑𝑖𝑒−𝑠ℎ = = 44 𝑘𝑁
sin(2𝛼)
𝐴1 𝜎𝑓𝑚 𝜀𝑒𝑞 𝜇𝑚
𝐹𝑚𝑎𝑛𝑑𝑟𝑒𝑙 = = 25 𝑘𝑁
tan(𝛼)
⇒ 𝐹 = 𝐹𝑖𝑑𝑒𝑎𝑙 + 𝐹𝑠ℎ𝑒𝑎𝑟 + 𝐹𝑑𝑖𝑒−𝑠ℎ + 𝐹𝑚𝑎𝑛𝑑𝑟𝑒𝑙 = 184 𝑘𝑁
b) Power requirement:
0.5𝑚
𝑃𝑜𝑤𝑒𝑟 = 𝐹. 𝑣 = (184𝑘𝑁) ( ) = 92 𝑘𝑊
𝑠
Problem 5:
A 4 mm sheet of annealed AZ-31B magnesium alloy is subjected to rolling operation at room
temperature, in which 200 mm diameter rollers are utilized in the forming process. The width
of the magnesium sheet is 500 mm, whereas the associated material properties are identified as
K=450 MPa and n=0.16. In addition, the coefficient of friction between the interface surfaces
is known to be 0.1.
a) If the rolls will just pull the sheet without any need for external support, calculate the
maximum thickness of the final sheets.
b) Using the final thickness of the rolling sheet found in the previous part, calculate the roll
force required in the operation.
c) Find the power requirement assuming that roll speed is 2.5 m/s.
Solution:
The parameters given in the question are listed as follows:
𝐾 = 450 𝑀𝑃𝑎 𝑛 = 0.16 𝑤 = 500 𝑚𝑚 𝜇 = 0.1
ℎ0 = 4 𝑚𝑚 𝐷 = 200 𝑚𝑚 𝑣𝑟𝑜𝑙𝑙 = 2.5 𝑚/𝑠
a) If the above condition is satisfied, the magnesium sheet is pulled by the roll without any
external force requirement:
tan(𝛼) ≤ 𝜇
In order for the rollers to just pull the magnesium sheet, the limiting case of the expression
should be considered, i.e. tan(𝛼) = 𝜇 . First of all, the angle can be calculated as follows:
ℎ0 − ℎ1 4 𝑚𝑚 − ℎ1
𝛼 = cos−1 (1 − ) ⇒ 𝛼 = cos −1 (1 − )
2𝑅 200 𝑚𝑚
Substitute it to the pulling condition expression:
tan(𝛼) = 𝜇 = 0.1 ⇒ 𝛼 = atan(𝜇) = atan(0.1) = 0.0997
4 𝑚𝑚 − ℎ1
⇒ 𝛼 = 0.0997 = cos −1 (1 − )
200 𝑚𝑚
4 𝑚𝑚 − ℎ1
⇒ 𝛼 = cos(0.0997) = 1 −
200 𝑚𝑚
⇒ ℎ1 = 3 𝑚𝑚
When the final thickness of the magnesium sheets is 3 mm (or smaller than 3 mm), the roll will
pull the sheet. Note that one will use that limiting value in the next part of the question.
b) The roll force is calculated with the following expression:
𝑃𝑟 = (1.15)𝐿𝑤𝑄𝜎𝑓𝑚
where
L: Length of the rolling contact region
w: Width of the sheet
Q: Pressure multiplication factor
𝜎𝑓𝑚 : Mean flow stress
The length of the rolling contact region is stated as the following relation, which can easily be
obtained by the roll geometry:
𝐿 = √𝑅(ℎ0 − ℎ1 )
⇒ 𝐿 = √(100𝑚𝑚)(1𝑚𝑚) = 10 𝑚𝑚
Width of the sheet is already given as 500 mm and it is assumed to be constant throughout the
process. 𝑤 = 500 𝑚𝑚
Pressure multiplication factor can be obtained regarding the partial or full plastification
condition. The corresponding formulas are given as follows:
Case 1: Partial Plastification (ℎ𝑚𝑒𝑎𝑛 /𝐿 > 1)
ℎ𝑚𝑒𝑎𝑛
𝑄 = 0.3 + 0.7
𝐿
Case 2: Full Plastification (ℎ𝑚𝑒𝑎𝑛 /𝐿 ≤ 1)
ℎ𝑚𝑒𝑎𝑛 ℎ 𝜇𝐿
𝑄= (𝑒 𝑚𝑒𝑎𝑛 − 1)
𝜇𝐿
In the question, we must first determine the ratio as
ℎ𝑚𝑒𝑎𝑛 ℎ0 + ℎ1 4𝑚𝑚 + 3𝑚𝑚
= = = 0.35 < 1
𝐿 2𝐿 20𝑚𝑚
In that case, full plastification formula should be used as follows:
ℎ𝑚𝑒𝑎𝑛 ℎ 𝜇𝐿
𝑄= (𝑒 𝑚𝑒𝑎𝑛 − 1)
𝜇𝐿
3.5 𝑚𝑚 (0.1)(10 𝑚𝑚)
⇒𝑄= (𝑒 3.5 𝑚𝑚 − 1)
(0.1)(10 𝑚𝑚)
⇒ 𝑄 = 1.157
The last term, which is the mean flow stress, can be found as
𝐾𝜀 𝑛 ℎ0
𝜎𝑓𝑚 = 𝑤ℎ𝑒𝑟𝑒 𝜀 = ln ( )
𝑛+1 ℎ1
Therefore, the value is calculated as follows:
4 𝑚𝑚 0.16
(450 𝑀𝑃𝑎) (ln (
3 𝑚𝑚 )
𝐾𝜀 𝑛 )
𝜎𝑓𝑚 = =
𝑛+1 1.16
⇒ 𝜎𝑓𝑚 = 318 𝑀𝑃𝑎
Finally, the roll force can be calculated using the values found previously:
𝑃𝑟 = (1.15)𝐿𝑤𝑄𝜎𝑓𝑚
⇒ 𝑃𝑟 = (1.15)(10 𝑚𝑚)(500 𝑚𝑚)(1.157)(318 𝑀𝑃𝑎)
⇒ 𝑃𝑟 = 2.115 𝑀𝑁
c) The power required for the rolling process is expressed as follows:
𝑣
𝑃𝑜𝑤𝑒𝑟𝑟 = 𝑃𝑟 𝐿
𝑅
2.5 𝑚/𝑠
⇒ 𝑃𝑜𝑤𝑒𝑟𝑟 = (2.115𝑀𝑁) (10 𝑚𝑚)
100𝑚𝑚
⇒ 𝑃𝑜𝑤𝑒𝑟𝑟 = 529 𝑘𝑊
Extra Info: Look at the Q&A document Chapter 5, pages 5.12-5.19, for further information
about rolling (for the initial grasp & derivation of the neutral point etc.).
Problem 6:
A hot rolling process with 200 mm radius rollers have been operated at 1600 ˚C to reduce the
thickness of an annealed steel slab form 50 mm to 45 mm. The width of the hot-rolled slab is
1000 mm, whereas the strength coefficient and strain rate sensitivity exponent are provided as
C=150 MPa and m=0.15, respectively. Note that coefficient of friction associated with the
operation is known to be 0.18.
a) What is the roll force requirement of the operation if the mean sheet velocity is 1.4 m/s?
b) If the roll velocity is known as 1.5 m/s, determine the amount of power needed for the hot
rolling process.
Solution: The parameters given in the question are listed as follows:
𝐶 = 150 𝑀𝑃𝑎 𝑚 = 0.15 𝑤 = 1000 𝑚𝑚 ℎ0 = 50 𝑚𝑚
𝑚𝑒𝑎𝑛
ℎ1 = 45 𝑚𝑚 𝑅 = 200 𝑚𝑚 𝜇 = 0.18 𝑣𝑠ℎ𝑒𝑒𝑡 = 1.4 𝑚/𝑠
a) The roll force is calculated with the below formulation:
𝑃𝑟 = (1.15)𝐿𝑤𝑄𝜎𝑓
where
L: Length of the rolling contact region
w: Width of the sheet
Q: Pressure multiplication factor
𝜎𝑓 : Flow stress given by the flow equation
The length of the rolling contact region is expressed as the following relation:
𝐿 = √𝑅(ℎ0 − ℎ1 )
⇒ 𝐿 = √(200 𝑚𝑚)(5 𝑚𝑚) = 31.6 𝑚𝑚
Width of the sheet is assumed to be constant throughout the process since 𝑤0 /𝐿 > 20
⇒ 𝑤 = 𝑤0 = 1000 𝑚𝑚
Pressure multiplication factor can be obtained regarding the partial or full plastification
condition.
In the question, the above ratio should be determined at first
ℎ𝑚𝑒𝑎𝑛 ℎ0 + ℎ1
= = 1.5 > 1
𝐿 2𝐿
Since the ratio is bigger than 1, partial plastification takes place in that case. Therefore, the
pressure multiplication factor is found as follows:
Case: Partial Plastification (ℎ𝑚𝑒𝑎𝑛 /𝐿 > 1)
ℎ𝑚𝑒𝑎𝑛
𝑄 = 0.3 + 0.7
𝐿
⇒ 𝑄 = 0.3(1.5) + 0.7 = 1.151
The flow stress is found by the equation written below:
𝑚𝑒𝑎𝑛
𝑚
𝑣𝑠ℎ𝑒𝑒𝑡 ℎ0
𝜎𝑓𝑚 = 𝐶𝜀̇ 𝑤ℎ𝑒𝑟𝑒 𝜀̇ = ln ( )
𝐿 ℎ1
Note that the mean velocity of the sheet is given as 1.4 𝑚/𝑠 in the question. Therefore, flow
stress can be calculated as follows:
0.15
1.4 𝑚/𝑠 50 𝑚𝑚
𝜎𝑓𝑚 = 𝐶𝜀̇ 𝑚 = (150 𝑀𝑃𝑎) (( ) ln ( ))
31.6 𝑚𝑚 45 𝑚𝑚
⇒ 𝜎𝑓 = 189 𝑀𝑃𝑎
Finally, the roll force can be calculated using the values found previously:
𝑃𝑟 = (1.15)𝐿𝑤𝑄𝜎𝑓𝑚
⇒ 𝑃𝑟 = (1.15)(31.6 𝑚𝑚)(1000 𝑚𝑚)(1.151)(189 𝑀𝑃𝑎)
⇒ 𝑃𝑟 = 7.91 𝑀𝑁
c) The power required for the rolling process is expressed as follows:
𝑣𝑟𝑜𝑙𝑙
𝑃𝑜𝑤𝑒𝑟𝑟 = 𝑃𝑟 𝐿
𝑅
𝑚
1.5 𝑠
⇒ 𝑃𝑜𝑤𝑒𝑟𝑟 = (7.91 𝑀𝑁)(31.6 𝑚𝑚) = 1875 𝑘𝑊
200 𝑚𝑚